STREET + 4X4 + PERFORMANCE “From Cast Iron to the Finished Product - Total Control“ Manufacturing Safety for Over 40 Years
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CATALOGUE - 2013 Disc Rotors / Drums version 2 ™ ™ STREET + 4x4 + PERFORMANCE “From cast iron to the finished product - total control“ Manufacturing safety for over 40 years “We are consistent in both quality After 30 years of design and development with race teams around the world, Disc Brakes Australia developed and performance. This is what a proprietary cast iron formulation ( XG-150 ) for use in Foundry separates us from the rest” all of it’s premium performance disc brake rotors. DBA’s grey iron is rich in carbon and alloyed to produce excellent thermal characteristics, which is a key factor in Phillip Joseph the production of the casting. This is combined with our Managing Director patented Kangaroo Paw ventilation design. With a supersaturated solution of carbon in an iron matrix, the excess carbon precipitates out in the form of graphite flakes. The structural distribution of these graphite flakes provide excellent thermal properties, increasing the thermal shock resistance. Raw Castings Also, when combined with DBA’s TSP process it allows Through many decades of manufacturing the material to cope with rapid thermal cycling with experience and unsurpassed knowledge through core-heat levels reaching approximately 700oC and above. research and development, DBA has positioned itself as Australia’s most awarded manufacturer and The DBA developed TSP™ process, stress relieves the cast iron during the manufacturing process. a global leader in brake rotor manufacturing. Unlike any other cast irons, the XG-150 formulation was developed to respond to the TSP process resulting in a Through continuous improvements in engineering rotor that is ideal for heavy duty braking and suitable for motorsport applications. Machining along with a thirst for innovation, DBA has managed to consistently re-define and deliver Mark Joseph braking solutions for an extensive range of vehicle XG-150 Features & Benefits Sales & Marketing Director Global distribution and warehousing applications and conditions. (USA) Feature Benefit High thermal conductivity Reduced brake fade, improved heat dissipation Consistent brake pedal feel Thermal Stability Minimises the risk of brake shudder/judder Packaging & Distribution DBA’s Kangaroo Paw Actual imported conventional straight vane rotor Kangaroo Paw. (to suit a large 4 door sedan vehicle) (to suit a large 4 door sedan vehicle) Conventional straight vane up to vs 59.7% Increased surface area Home grown increase in surface area defl ection between vanes DBA’s Kangaroo Paw better heat inspiration. dissipation cooling system Kangaroo Paw 144 pillars Inspired within Australia’s heartland, DBA Other than material composition, another almost conventional straight vanes developed the Kangaroo Paw cooling major factor that affects the thermal system. This patented ventilation system 10% performance of brake rotors is the provides a much more efficient method greater mass minimises of keeping the rotors cool under the brake fade surface area within the ventilation heaviest of braking applications. design. The more surface area, the more DBA’s Kangaroo Paw System Conventional Straight Vane heat that can be removed from the Using a series of 144 diamond and brake rotor. teardrop patterned pillars (or columns) Even distribution of pillars poor casting quality instead of conventional straight cooling The mass of the brake rotor also plays an vanes, the design increases cooling distance between pillars too wide efficiency by up to 20% when compared important role. The greater the mass, the with most other conventional ventilated more heat that can be stored and must disc rotors. be dissipated, this is why the design of the Kangaroo Paw is so effective. This minimises As well as providing cooler conditions, the the risk of brake fade and restores normal Kangaroo Paw system also provides additional braking much sooner. support to the friction face. This enables the rotor Controlled casting quality to maintain the fine tolerances over the life of the rotor better than a straight vane design, which can vane distance from the edge too far - reduces strength of the rotor “balloon” and swell between the vanes when operating A typical conventional at high temperatures. straight vane rotor Thick-and-thin friction The Kangaroo Paw pillars are evenly spread across the disc face and face is a result of poor make the rotor stronger, more stable and more consistent in operation. casting control and can affect braking performance Straight Vane Comparing the ventilation air space between friction faces of a DBA Kangaroo Paw design and a conventional straight vane sample The ventilation system of a brake rotor is best described as the Kangaroo Paw foundation and support between the friction surfaces. A recent discovery has Increased distance found that “lightweight” between vanes inferior discs have reduced reduces surface braking plate surface Feature Kangaroo Paw Straight Vane area which will thickness. This is a common affect the rotors method employed to 2 2 ability to dissipate reduce manufacturing costs. Surface Area 12,937 mm 8,100 mm = 37.3% less surface area heat The result is lower thermal mass causing unpredictable Weight 8.28 kg 7.68 kg = 7.25% less mass performance characteristics and sacrificing safety and No. of Pillars 144 36 = 75% less support Straight Vane longevity. Better materials, better processes... Behind every great wheel should be a great brake disc The technologies employed by DBA are at the forefront of brake manufacturing and allows consumers to clearly Patented design – ‘Kangaroo Paw’ is a patented hi-tech disc identify why DBA discs are ultimately superior. The processes adopted by DBA through clever engineering allow rotor ventilation system which features a series of 144 diamond consistent and premium performance characteristics, making DBA brake discs do and tear drop shaped pillars individually spaced between the what they do best, slow down vehicles! rotor faces. This design cools the rotor faster and increases dimensional strength and stability across the disc rotor. Defining elements of DBA discs: Dimensionally Precise – Most discs on the market are found to be Performance metals – Usually only found in high-end ‘ground’ finished, but every DBA disc endures a special Cubic Boron Nitride performance discs, XG-150 is a unique formulation developed for (CBN) fine-turn process. The quality of the finish is measured as a surface all DBA products. High carbon alloyed iron may look like regular Cubic boron nitride (CBN) is roughness (engineering term Ra) in microns. known to be the second hardest iron found on standard discs, but DBA’s unique XG-150 iron material after diamond One micron is 1 millionth of a metre (see diagram below). formula has been tested the world over to the absolute limits of Graphite flakes in the microstructure of the DBA rotors are machined to a maximum of 1.8 Ra or less. braking punishment. XG-150 cast iron Built for abuse – DBA uses a process called thermal stability profiling (TSP) on all HD and CLUBSPEC discs manufactured with XG-150. TSP re-aligns the micro-structure of the iron increasing How big A human hair density, resistance to extreme heat and reducing disc wear. (magnified in comparison) Initial When the rotor The colour Colour exceeds this temperature: will change to: is a Micron? Thermo-graphic paint markings allow clear 1.8 Ra Micron 458ºC / 856ºF identification of disc temperature and disc 550ºC / 1022ºF performance. 630ºC / 1166ºF DBA’s Cubic Boron Nitride ‘Ground’ finished rotors (fine-turn) rotor surface Protection in packaging – DBA delivers added value to ensure their products are received in perfect condition by covering each and every disc in a moisture proof, corrosion protective dual layer package. Premium discs, premium appeal – The premium paint coating found on all DBA discs* in non-friction areas ensures corrosion protection. DBA discs aid vehicle Magnified view of the surface finish Magnified view of the surface finish appearance and last longer against the elements. *excludes street series OE replacement discs CBN finishing ensures an even pad transfer layer deposition which is important for the modern brake pad. This leads to a better pedal feel and eliminates the possibility of pad ‘knock’. Premium paint coating on non-friction surfaces ™ Unique to the ClubSpec 4000 and 5000 series rotors A new standard in slot design A new breed of performance braking DBA’s T2 has greater braking advantages over the traditional straight slot designs. DBA’s T3 slot design is built on the T2 design but with an increased number of slots, taking it from 32 to 48 CNC machined slots. The Bi-Symmetrical curve slots dampen the vibration harmonics or noise, resulting in a quieter, more responsive and smoother brake pedal feel. The result is an even quieter, more responsive and smoother brake pedal feel. This is achieved from a series of tri- symmetrical ‘curved’ slots, which when aligned in a specific way, drastically dampen the vibration harmonics, that’s In addition, the T2 increases the number of out-gassing exit points, allowing friction gasses to escape and enhancing commonly associated with traditional straight slot (groove) rotor designs. The tri-symmetrical slots also increase the the pad bite. number of out-gassing exit points for brake pad friction gases to escape through, further increasing the consistency and effectiveness of every brake stop. ™ ™ Feature Advantages Benefits Feature Advantages Benefits Bi-Symmetrical curve slots dampens the vibra- A quieter, responsive and smoother brake Tri-Symmetrical curve slots dampens the vibra- A quieter, responsive and smoother brake T2 tion harmonics pedal feel T3 tion harmonics pedal feel 32 precision Universal slot design Eliminates the need for left and right discs 48 precision Universal slot design Eliminates the need for left and right discs CNC machined Increased number of out-gassing exit points for Increases the consistency and effective- CNC machined Increased number of out-gassing exit points for Increases the consistency and effectiveness slots brake pad friction gasses to escape through ness of every brake stop.